Heat-able On-the-Go Food Products Apparatus and Method

ABSTRACT

A molded pulp base container sprayed with a barrier and a sealant layer, used as a heatable package for on-the-go (OTG) food products is disclosed. The container by itself, in one embodiment, is used for microwave/oven heating the food contents in the container, eliminating the need for a separate susceptor or an additional package for heating. The inside surface of the container is spray coated with a food safe poly layer to create a moisture/oxygen barrier for shelf life stability. A sealant layer is directly applied on top of the barrier layer to provide hermesicity for the container. Adding a brine solution and a percentage of sodium to the finished package formulation, selectively heats the food contents of the package while keeping the package itself cool enough to handle. In another system embodiment, a condiment package is fitted to a formed top of the container.

PRIOR ART AND BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to an on-the-go food package that ishermetically sealed to facilitate heating of the contents of the packageand barrier protected for extended shelf life of the contents.

2. Prior Art Background

Modern society is on the go, and there is plenty of demand for a quickbite at all times of the day. Busy citizens demand quick meal options.There is a need for quick on-the-go (OTG) foods that can be heated in amicrowave or turbochef.

It is also desirable to consume some food products at temperatures aboveroom temperature. This is frequently the case when a food that has beencooked is being consumed. Ideally, a consumer wants to eat the foodshortly after it has been prepared so it is still warm. The on-the-gofood products are typically heated in a microwave, on a stove, inside ahot air oven, or other known heating method, shortly before they areconsumed. Similarly, many examples of commercially availablerefrigerated and frozen foods exist in the marketplace, which are alsoheated shortly before consumption.

On-the-go food products, such as pasta, noodles, rice, pizza, soups,sandwiches, tortilla chips, instant oatmeal, cereals, grits, and potatofries are typically sold to consumers in individual single serving ormultiple serving packages from convenience stores or grocery stores. Thefood products are typically packaged in non-microwavable packages.Therefore, the food products need to be transferred into amicrowavable/heat-able container and then heated before consumption.Currently, heating is accomplished by adding a separate susceptor or anadded package container for heating. Some food packages provide amicrowavable/heat-able container as a separate piece in the overallpackage. Most convenience and grocery stores provide microwave oven orturbochef oven for heating. However, prior art fails to disclosepackaged direct contact food which is microwaveable/heat-able using theactual packaging itself to create/control the product heating in themicrowave oven. Consequently, a need exists for a package of food thatallows a consumer to directly heat and consume the food products inside.

In the case of on-the-go food products, cooking and packaging technologyenables market participants to store and sell on-the-go food productsfor weeks or months at room temperature after they have been cooked,before they lose their desirable organoleptic properties, become stale,or become microbially unstable. Such products are known in the industryas shelf stable food products. Shelf stable food products requirepackaging with sufficient barrier properties to moisture and oxygenmigration in order to keep the food products from becoming microbiallyunstable.

Prior art fails to disclose an on-the-go food product/package that hasdirect food contact, shelf stable with moisture/oxygen barrier,hermetically heat sealed, multiple product combinations mealreplacement, microwave and turbochef oven cooking safe.

Consequently, there is a need for an on-the-go food container thataccomplishes the following objectives:

-   -   Provide for an on-the-go packaged direct contact food which is        microwaveable using the actual package itself to create/control        the product heating in the microwave oven.    -   Provide for an on-the-go food products for producing “food grade        packaging” that could be heated by itself without affecting the        shelf life.    -   Provide for an on-the-go food products with food grade sealant        material that can hermetically seal and shut the container.    -   Provide for an on-the-go food products with food grade sealant        material that can be spray coated for easy separation during        recycling process.    -   Provide for an on-the-go food products with food grade material        that acts as a barrier to both oxygen and moisture migration        products.    -   Provide for an on-the-go food products with additives to the        container material to control the rate of heating of the package        and the food contents.    -   Provide for an on-the-go food products with additives to the        container material to reduce cook time for the food products.    -   Provide for an on-the-go food product container manufacturing        methods comprising eco-friendly and minimally waste producing        process steps.

While these objectives should not be understood to limit the teachingsof the present invention, in general these objectives are achieved inpart or in whole by the disclosed invention that is discussed in thefollowing sections. One skilled in the art will no doubt be able toselect aspects of the present invention as disclosed to affect anycombination of the objectives described above.

BRIEF SUMMARY OF THE INVENTION

The present invention in various embodiments addresses one or more ofthe above objectives in the following manner. The invention includes amolded pulp base container sprayed with a barrier and a sealant layer,used as a heat-able package for on-the-go (OTG) food products. Thecontainer by itself, in one embodiment, is used for microwave/ovenheating the food contents in the container, eliminating the need for aseparate susceptor or an additional package for heating. The insidesurface of the container is spray coated with a food-safe poly layer tocreate a moisture/oxygen barrier for shelf life stability. A sealantlayer is directly applied on top of the barrier layer to providehermesicity for the container. Adding a brine solution and a percentageof sodium to the finished package formulation, selectively heats thefood contents of the package while keeping the package itself coolenough to handle. In another system embodiment, a condiment package isfitted to a formed top of the container.

The present invention system may be utilized in the context of method ofmaking a heat-able container for storing and heating food, the methodcomprises the steps of:

-   -   (1) mixing a pulp slurry;    -   (2) molding a container comprising a formed top from the pulp        slurry;    -   (3) drying the molded container;    -   (4) spraying a barrier layer directly to an inside surface of        the molded container;    -   (5) drying the molded container;    -   (6) spraying a sealant layer directly on top of the barrier        layer;    -   (7) drying the container;    -   (8) curing the container;    -   (9) adding food products into the container; and    -   (10) sealing said container with the formed top.

Integration of this and other preferred exemplary embodiment methods inconjunction with a variety of preferred exemplary embodiment systemsdescribed herein in anticipation by the overall scope of the presentinvention.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the advantages provided by the invention,reference should be made to the following detailed description togetherwith the accompanying drawings wherein:

FIG. 1 is a perspective view illustrating a heat-able food package witha closed formed top according to an exemplary embodiment of the presentinvention.

FIG. 2 is a perspective view illustrating a heat-able food package withan open formed top according to an exemplary embodiment of the presentinvention.

FIG. 3 is a perspective view illustrating a heat-able food package witha condiment package fitted inside according to an exemplary embodimentof the present invention.

FIG. 4 is a perspective view illustrating a heat-able food package witha condiment package fitted to the outside surface of the formed topaccording to an exemplary embodiment of the present invention.

FIG. 5 is a cross-sectional view illustrating a barrier layer and asealant layer according to an exemplary embodiment of the presentinvention.

FIG. 6 is a perspective view illustrating a circular bowl shapedheat-able food package with a closed formed top according to anexemplary embodiment of the present invention.

FIG. 7 illustrates a flowchart for manufacturing on-the-go heat-ablefood package according to an exemplary embodiment of the presentinvention.

DESCRIPTION OF THE PRESENTLY EXEMPLARY EMBODIMENTS

While this invention is susceptible of embodiment in many differentforms, there is shown in the drawings and will herein be described indetailed preferred embodiment of the invention with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention and is not intended to limit the broadaspect of the invention to the embodiment illustrated.

The numerous innovative teachings of the present application will bedescribed with particular reference to the presently exemplaryembodiment, wherein these innovative teachings are advantageouslyapplied to the particular problems heat-able on-the-go food productsapparatus and method. However, it should be understood that thisembodiment is only one example of the many advantageous uses of theinnovative teachings herein. In general, statements made in thespecification of the present application do not necessarily limit any ofthe various claimed inventions. Moreover, some statements may apply tosome inventive features but not to others.

Exemplary Embodiment Heat-able Package (1000-2000)

The term “on-the-go food product” as used herein is defined as a foodproduct that is consumed for snacking or meal purposes. The term“microwavable” as used herein is any container/vessel that can be safelyused without degrading/deforming in a microwave as recommended byregulatory standards. It should be noted that the term “package”,Package container“, and “container” are used inter-changeably toindicate an article that is shaped to hold food products.

One aspect of the present invention provides consumers with a directcontact food package purchased at grocery or convenience stores which ismicrowaveable/heat-able using the actual packaging itself. Anotheraspect of the present invention involves adding salt and/or brinesolution to the container to create/control the OTG food product heatingin the microwave or hot air oven. The present invention is also directedtowards a method of heating food products such as tortilla chips andoatmeal using microwave energy, in a microwave oven or a hot air ovensuch as turbochef.

The microwave oven is an appliance that can be found in many homes andbusinesses. During operation, a microwave oven floods the cookingchamber with non-ionizing microwave radiation, usually at a frequency ofabout 2.45 GHz. Another commonly used microwave frequency is 915 MHz.The power level of most consumer grade microwaves varies from about 900Watts to about 1400 Watts.

Many food molecules (for example water molecules) are electric dipoles,which means they are positively charged at one end and are negativelycharged at the other end. As the microwave radiation passes through thefood, the dipole molecules rotate as they try to align themselves withthe alternating electric field of the microwaves. This rotation andmovement causes the food to heat up as the rotating molecules impactother molecules, putting them into motion. Microwave heating is highlyefficient on liquid water (which is a relatively polar molecule), andmuch less so on fats and sugars (which are less polar).

The microwave radiation can be produced by a cavity magnetron, anddirected into the food chamber through a waveguide. The waveguide inmost small, consumer grade microwaves directs the microwave radiationinto the food chamber from one side of the food chamber, usually at alocation between the middle and the top of the food chamber. Themicrowave radiation generally reflects off the walls of the foodchamber, but is absorbed by any water-bearing food present in the foodchamber, thereby exciting the water molecules. The radiation reflectingaround inside the food chamber forms an approximately uniform heatingenvironment, with some localized hotspots due to constructive and/ordestructive interference between microwaves.

The term “hot air oven” as used herein is a control system thatprecisely coordinates impinged air (which evenly browns the outside offood) with microwave energy (which evenly cooks the inside) to rapidlycook food without compromising quality. Some examples of hot air ovensare products manufactured by TurboChef Technologies, Inc.

Applicants herein have created a food package that enables a consumer toheat OTG food product in the microwave or a hot air oven without theneed for an additional microwavable susceptor in the package. In oneembodiment, the package is a microwave-safe container that comprises apulp material, wherein the inner surface of the container is coated witha barrier layer and a sealant layer. There are a number of embodimentsof this invention which fall within the scope of the invention in itsbroadest sense.

The present invention may be seen in more detail as generallyillustrated in FIG. 1 and FIG. 2, wherein a heat-able container (1001)comprising a paper pulp material shaped shell to hold said food and a“closed” formed top (1003) attached to a bottom portion (1004). Asillustrated in FIG. 2 (2000), the container (2001) comprises an “opened”formed top (2003) attached to a bottom portion (2004). The formed top(2003) may be attached to the bottom portion (2004) of the container(2001) in such a way as to enable the formed top (2003) to open and/orclose the container about a common axis (2006). FIG. 1 illustrates aclosed position of the formed top (1001) and FIG.2 illustrates an openedposition of the formed top (2001).

Similar to the generally illustrated rectangular shaped container inFIG.1, a bowl shaped heat-able shell (6001) made of paper pulpcomprising a “closed” formed top (6003) attached to a bottom base (6004)is illustrated in FIG.6 (6000).

The pulp packaging material, in a preferred exemplary embodiment, ismade from 100% post-industrial raw materials and no chemicals are addedduring the pulping process. According to an exemplary embodiment, thepulp material composition comprises water, natural emulsified wax, andrecycled corrugate material. For example, the composition may be 5%natural emulsified wax, 10% water, and 80% recycled corrugate material.In another example, the composition may be 20% natural emulsified wax,10% water, and 70% recycled corrugate material. The composition may bein the range of 1-20% natural emulsified wax, 1-30% water, and 50-95%corrugate material. Typical uses of molded products are for packagingelectronic equipment, cellular phones, and other household and hardwareitems. Very high-capacity, high-speed molding equipment is used toproduce drink trays, cup carriers, wine shippers, egg cartons, eggtrays, pulp bedpan liners, fruit trays, slipper pans, end caps, etc.But, pulp material has not been used for “direct contact” foodpackaging.

Applicants herein have created a food package with pulp material thathas other properties such as:

-   -   moisture absorption to absorb sprayed barrier;    -   adhesion to enable a barrier layer to stick to the rough side of        the fibrous material;    -   insulation to keep the outside of the package warm enough after        heating, such that a container can be held by a human without        substantially causing burn;    -   lower weight so that it is easily held;    -   recyclable and eco-friendly as it is bio-degradable;    -   moldable from a commonly available pulp slurry;    -   waste-free manufacturing due to minimal water use and recycling        used in the process;    -   rigid properties to sufficiently withstand shipping and        handling;    -   thermally stable to withstand microwave and hot air heating up        to 500° C.; and    -   environmentally safe due to insignificant outgassing of toxic        chemicals. The levels are insignificant as deemed by        environmental regulatory agencies.

According to one exemplary embodiment, the inside surface of the shellis coated with a barrier layer that reduces the rate of moisture andoxygen migration through the container. The barrier layer may be neededto keep the food products fresh and also keep the food from becomingmicrobially unstable. In addition, the barrier layer may help extend theshelf life of the package, in some cases by more than 6 months. In oneexemplary embodiment, the barrier layer is made from a material such asMichem® Coat 95 manufactured by Michelman, Inc. The material may bewater-based coatings that are selected primarily for grease and oilresistance. Other benefits of the Michem® Coat 95 material include waterresistance, release, coldset gluability, hot melt, gluability, andrecyclability. The barrier layer has thermal properties to withstandheat in a microwave or hot air oven and also adhesive properties tostick to the fibrous side of the container (2002). The barrier layermaterial is also food safe.

According to yet another exemplary embodiment, a sealant layer that isfood safe is directly applied on top of the barrier layer. The sealantlayer is exposed to the “food side” and is in direct contact with thefood contents. The sealant layer material, in one preferred exemplaryembodiment, is MICHEM COAT 1398.E manufactured by Michelman, Inc. Theproperties of which are shown below

Classification REACH Chemical Classification CLP EC No. RegistrationName CAS-No EC-No Weight % (1999/45/EC) 1272/2008 Number AMMONIUM1336-21-6 215-647-6 <1 C: R34 Skin Corr. 1B 01-2119488876-14 HYDROXIDEN: R50 (H314) Aquatic Acute 1 (H400) STOT SE 3; H335: C = 5%

A cross-section of the inside surface after the application of thebarrier and sealant layers is illustrated in FIG. 5 which will bediscussed further below. According to yet another exemplary embodiment,multiple barrier and sealant layers may be sprayed to achieve thedesired leakage and barrier properties.

According to a further exemplary embodiment, addition of a brinesolution or adding a percentage of sodium to the finished packageformulation controls the moisture content of the package. According to apreferred exemplary embodiment, the percentage of salt in the finishedpackage formulation may range from 0-40% by weight. According to a morepreferred exemplary embodiment, the percentage of salt in the finishedpackage formulation may range from 0-20% by weight. According to a mostpreferred exemplary embodiment, the percentage of salt in the finishedpackage formulation may range from 0-10% by weight. The salt contentwithin the package formulation may work with the microwave oven toactivate the molecules to heat the product inside the pulp package. Theadded sodium in the pulp package helps drive the heat towards the foodcontents in the inside of the package while keeping the outsiderelatively cooler. This assists with the handling of the package with ahuman hand after the package has been removed from the microwave or hotair oven.

The thickness of the pulp layer may be varied to alter the thermalcharacteristics such that the food contents are rapidly heated whilekeeping the container cool. In one exemplary embodiment, the thicknessof the pulp layer is between 1 mil and 50 mils. In a preferred exemplaryembodiment, the thickness of the pulp layer is between 20 mils and 40mils. In the most preferred exemplary embodiment, the thickness of thepulp layer is between 25 mils and 35 mils. For example, the thicknessmay be increased to reduce the cook time. According to yet anotherexemplary embodiment, thermal characteristics of the container may bechanged to cook food contents rapidly with the salt additive, brinesolution additive, and/or varying the thickness of the pulp materials orcombinations thereof. The formed top (2003) may also be used as awarming tray for added condiments to be heated. In addition, the bottomportion of the container may have a seat (2005) extended around theperimeter may be shaped to accept/seat a condiment package. Theformulation will allow more control of the product heating withoutintroducing any additional components to the finished package.

Embodiments of the present invention will also work withconfectionaries, candies, cookies, and other food products that peopledesire to consume at temperatures above the temperature at which theyare sold or stored.

Exemplary Embodiment Heat-able Container with Condiment Package(3000-4000)

As generally illustrated in FIG. 3 (3000) a condiment package (3006) maybe positioned/seated on a seat (3007) inside a heat-able containerpackage (3001). The heat-able container (3001) comprises a closed formedtop (3003) attached to a bottom portion (3004). The condiment package isshaped to mate with the heat-able container package (3001). According toan exemplary embodiment, the condiment package (3006) may be made ofpaper pulp and may be heated together with the container (3001) in amicrowave or a hot air oven. A divider (3008) may divide the condimentpackage into partitions (3009) to provide space for individualcondiments. For example, the container may contain tortilla chips andthe condiment package may be filled with cheese and jalapenos' inindividual compartments/partitions. In another example, the containermay contain oatmeal and the condiment package may be filled with nutsand fruits in individual compartments/partitions. It should be notedthat the two partitions (3009) in the condiment package (3006) shown inFIG. 3 (3000) are for illustration purposes only and may not beconstrued as a limitation. The condiment package may be partitioned intomore than one partition. Similar to the aforementioned package (2000),the inside surface (3002) of the container package (3001) is coated witha barrier layer and a sealant layer that is exposed to the food side.

Similar to the condiment package in FIG. 3 (3000), a condiment packagemay be positioned on top of the formed top of a heat-able containerpackage (4001) as illustrated in FIG. 4 (4000). The heat-able container(4001) comprises a formed top attached to a bottom portion (4004).According to an exemplary embodiment, the condiment package (4006) maybe made of paper pulp and may be heated together with the container(4001). The condiment package (4006) may also be made from plastic thatis transparent and enables a consumer to see the condiments through thepackage (4006). A divider (4008) may divide the condiment package intopartitions (4009) so that space is provided for individual condiments.For example, the container may contain tortilla chips and the condimentpackage may be filled with cheese and jalapenos in individualcompartments/partitions. In another example, the container may containoatmeal and the condiment package may be filled with nuts and fruits inindividual compartments/partitions. It should be noted that the twopartitions (4009) in the condiment package (4006) shown in FIG. 4 (4000)are for illustration purposes only and may not be construed as alimitation. The condiment package (4006) may be partitioned into morethan one partition. A packaging label may be affixed and wrapped aroundthe condiment package (4006) and the container (4001). Similar to theaforementioned package (2000), the inside surface of the container(4001) may be coated with a barrier layer and a sealant layer that isexposed to the food side.

Exemplary Embodiment Barrier layer and Sealant Layer Cross Section(5000)

As illustrated in FIG. 5 (5001), a cross section of a side of anon-the-go food package/container is shown. The pulp material layer(5012) has a smooth outside surface (5003) and a corrugated fibrousinside surface. A barrier layer (5011) that adheres to the fibroussurface may be spray coated with a spray head. Spray coating has theadvantage of getting more coverage compared to a laminate coating. Thespray coated barrier layer also delaminates from the fibrous pulp layerin a conventional recycling process when the package is disposed. Asealant layer (5010) is directly applied on top of the barrier layer.The sealant layer (5010) is food safe, and therefore is exposed to thefood side (5002) of the package. The sealant layer (5010) may have amaterial composition comprising ammonium hydroxide that is consideredfood safe. It should be noted that a single barrier layer (5011) and asingle sealant layer (5010) as shown in FIG. 5 (5001) are forillustration purposes only and may not be construed as a limitation.Multiple barrier layers and sealant layers may be alternatively appliedto the inside surface of the pulp container. After a first barrier layerand a first sealant layer is applied and cured, the layers may becombined and compressed into one layer for subsequent applications. Thesecond and subsequent barrier and sealant layers are applied directly ontop of the compressed layer. According to an exemplary embodiment, thesealant layer and the barrier layer may one layer that provides bothbarrier and sealing properties. According to an exemplary embodiment,applicants herein disclose an on-the-go food product/package that hasdirect food contact, shelf stable with moisture/oxygen barrier, and thatis hermetically heat sealed with the sealant layer. In a preferredexemplary embodiment, the barrier layer provides less than 0.5gm/pkg/day moisture vapor transmission rate (MVTR) and less than 2.0cc/pkg/day oxygen transmission rate (OTR). In another exemplaryembodiment, the weight of the pulp container only is less than 30 gramsand the combined weight of the container and one layer of sealant onelayer of barrier is less than 40 grams. In yet another exemplaryembodiment, the weight of the pulp container is less than 60 grams. Inyet another preferred exemplary embodiment, the weight of the pulpcontainer, sealant layer, and barrier layer is less than 80 grams. In apreferred exemplary embodiment, the thickness of the container pulp wallis in between 25 mils and 50 mils. In a more preferred exemplaryembodiment, the thickness of the container pulp wall is in between 15mils and 75 mils. In the most exemplary embodiment, the thickness of thecontainer pulp wall is less than 35 mils and the combined thickness ofthe barrier layer and sealant layer is less than 6 mils. In anotherpreferred exemplary embodiment, the combined thickness of the barrierlayer and sealant layer is less than 4 mils.

According to a preferred exemplary embodiment, the sealant layer and thebarrier layers are food safe up to 500° C.

On-The-Go Heat-able Package Manufacturing Method Exemplary Embodiment(7000)

A method of making a heat-able container for storing and heating food isillustrated in FIG.7 (7000). The method may be generally described interms of the following steps

-   -   (1) mixing a pulp slurry (7001);        -   Raw materials comprising natural emulsified wax and recycled            corrugate material such as paper pulp or cardboard may be            loaded into a pulper that mixes the materials with water to            produce pulp slurry. For example, the composition of the            slurry may be 5% natural emulsified wax, 10% water, and 80%            recycled corrugate material. The pulp slurry may be pumped            to a storage tank. A refiner and a 3 function cyclone            cleaner in combination with a vibrating screen may be            utilized to refine the pulp slurry to remove undesired            components. The refined pulp slurry may be further pumped to            a storage tank and then loaded into a mixer for consistency            control. Additives such a salt and brine solution are added            to the slurry, in one preferred exemplary embodiment. The            percentage salt may range from 1-25% by weight. The refined            and consistent pulp slurry may then be pumped to a molding            station. The excess water may be recycled and pumped to the            pulper or mixer so as to not generate waste water. Excess            pulp may be pumped back to the pulper so that insignificant            manufacturing waste is generated.    -   (2) molding a container comprising a shell and a formed top from        the pulp slurry (7002);        -   The consistent pulp slurry may be pulled through a mold that            screens on the inside of the mold. The mold may be shaped            consistent with the desired container shape. For example the            mold may be shaped as a rectangular bowl as shown in FIG.1            (1000) or a rounded bowl as shown in FIG.6 (6000). The            thickness of the pulp layer in the container may be in some            instances range from 15-75 mils.    -   (3) drying the molded container (7003);        -   The molded container from the step (7002) may be dried to            drive out excess moisture.    -   (4) spraying a barrier layer directly to an inside surface of        the molded container (7004);        -   A barrier layer may be sprayed directly on the inside            surface of the molded container with a spray head. The            thickness of the barrier layer may be determined by factors            such as desired shelf life, type of food contents, and            combinations thereof. The thickness of the barrier layer may            be in some instances range from 1-10 mils. The barrier layer            may be made from a material such as Michem® Coat 95            manufactured by Michelman, Inc.    -   (5) drying the molded container (7005);        -   The molded container from the step (7004) may be dried to            drive out excess moisture.    -   (6) spraying a sealant layer directly on top of the barrier        layer (7006);        -   A sealant layer may be sprayed directly on the inside            surface of the molded container with a spray head. Spray            application requires less material than a laminate            application. In addition, spray applied material easily            peels off during the recycling process. The thickness of the            sealant layer may be determined by factors such as desired            shelf life, type of food contents and combinations thereof.            The thickness of the sealant layer may be in some instances            range from 1-10 mils. The sealant layer may have composition            that includes ammonium hydroxide.    -   (7) drying the container (7007);    -   (8) curing the container (7008);        -   The dried container from the step (7007) may be cured in a            heated mold to provide strength to the container.    -   (9) adding food products into the shell (7009); and    -   (10) sealing the container with the formed top (7010).

This general method summary may be augmented by the various elementsdescribed herein to produce a wide variety of invention embodimentsconsistent with this overall design description.

System Summary

The present invention system anticipates a wide variety of variations inthe basic theme of a heat-able container for storing and heating foodtherein, the container comprising a paper pulp material shaped to holdthe food, a barrier layer and a sealant layer applied to an insidesurface of the container; the barrier layer sandwiched between thesealant layer and the inside surface of the container.

This general system summary may be augmented by the various elementsdescribed herein to produce a wide variety of invention embodimentsconsistent with this overall design description.

Method Summary

The present invention method anticipates a wide variety of variations inthe basic theme of implementation, but can be generalized as a method ofmaking a heat-able container for storing and heating food, the methodcomprises the steps of:

-   -   (1) mixing a pulp slurry;    -   (2) molding a container comprising a formed top from the pulp        slurry;    -   (3) drying the molded container;    -   (4) spraying a barrier layer directly to an inside surface of        the molded container;    -   (5) drying the molded container;    -   (6) spraying a sealant layer directly on top of the barrier        layer;    -   (7) drying the container;    -   (8) curing the container;    -   (9) adding food products into the container; and    -   (10) sealing the container with the formed top.

This general method summary may be augmented by the various elementsdescribed herein to produce a wide variety of invention embodimentsconsistent with this overall design description.

System/Method Variations

The present invention anticipates a wide variety of variations in thebasic theme of on-the-go heat-able packages. The examples presentedpreviously do not represent the entire scope of possible usages. Theyare meant to cite a few of the almost limitless possibilities.

This basic system and method may be augmented with a variety ofancillary embodiments, including but not limited to:

-   -   An embodiment wherein addition of brine solution changes thermal        characteristics of said paper pulp material to facilitate        selective said food heating.    -   An embodiment wherein addition of salt changes thermal        characteristics of said paper pulp material to facilitate        selective food heating.    -   An embodiment wherein said barrier layer moisture vapor        transmission rate (MVTR) is less than 0.5 gm/package/day.    -   An embodiment wherein said barrier layer oxygen transmission        rate (OTR) is less than 2 cc/package/day.    -   An embodiment wherein said sealant layer hermetically seals said        container.    -   An embodiment wherein said barrier layer is food safe.    -   An embodiment wherein said sealant layer is food safe.    -   An embodiment wherein said barrier layer is configured to extend        said package shelf life by at least 6 months.    -   An embodiment wherein the heat-able container further comprises        a condiment package that is shaped to fit outside a formed top        of said container.    -   An embodiment wherein the heat-able container further comprises        a condiment package that is shaped to fit inside a formed top of        said container.    -   An embodiment wherein said condiment package is made from        plastic.    -   An embodiment wherein said condiment package is made from        thermal formed pulp.    -   An embodiment wherein said container and said condiment package        are heated together.    -   An embodiment wherein said formed top is configured to warm said        condiment package contents.    -   An embodiment wherein said condiment package comprises at least        one partition.    -   An embodiment wherein the heat-able container further comprises        plural sealant layers and plural barrier layers.    -   An embodiment wherein said container is heated in a microwave.    -   An embodiment wherein said container is heated in a hot air        microwave oven.    -   An embodiment wherein said container weight is less than 30        grams.    -   An embodiment wherein the combined weight of said container,        said sealant layer, and said barrier layer is less than 40        grams.    -   An embodiment wherein said container wall thickness is less than        35 mils.    -   An embodiment wherein the combined thickness of one layer of        said sealant layer and said barrier layer is less than 6 mils.

One skilled in the art will recognize that other embodiments arepossible based on combinations of elements taught within the aboveinvention description.

What is claimed is:
 1. A heat-able container for storing and heatingfood therein, said container comprising a paper pulp material shapedshell to hold said food, a barrier layer and a sealant layer applied toan inside surface of said shell; wherein said barrier layer issandwiched between said sealant layer and said inside surface of saidshell; and said sealant layer is food safe.
 2. The heat-able containerof claim 1, wherein said paper pulp material comprises salt.
 3. Theheat-able container of claim 1, wherein said barrier layer moisturevapor transmission rate (MVTR) is less than 0.5 gm/package/day.
 4. Theheat-able container of claim 1, wherein said barrier layer oxygentransmission rate (OTR) is less than 2 cc/package/day.
 5. The heat-ablecontainer of claim 1, wherein said sealant layer hermetically seals saidcontainer.
 6. The heat-able container of claim 1, wherein said barrierlayer is food safe up to 500° C.
 7. The heat-able container of claim 1,wherein said sealant layer is food safe up to 500° C.
 8. The heat-ablecontainer of claim 1 further comprises a condiment package that isshaped to fit outside a formed top of said container.
 9. The heat-ablecontainer of claim 1 further comprises a condiment package that isshaped to fit inside said container.
 10. The heat-able container ofclaim 9, wherein said condiment package is made from plastic.
 11. Theheat-able container of claim 9, wherein said condiment package is madefrom thermal formed pulp.
 12. The heat-able container of claim 9,wherein said formed top is configured to warm said condiment packagecontents.
 13. The heat-able container of claim 9, wherein said condimentpackage comprises at least one partition.
 14. The heat-able container ofclaim 1 further comprises plural sealant layers and plural barrierlayers.
 15. The heat-able container of claim 1 wherein said containerweight is less than 30 grams.
 16. The heat-able container of claim 1wherein the combined weight of said container, said sealant layer, andsaid barrier layer is less than 40 grams.
 17. The heat-able container ofclaim 1 wherein said container wall thickness is less than 35 mils. 18.The heat-able container of claim 1 wherein the combined thickness of onelayer of said sealant layer and said barrier layer is less than 6 mils.19. A method of making a heat-able container for storing and heatingfood, said method comprises the steps of: (1) mixing a pulp slurry; (2)molding a container comprising a formed top from said pulp slurry; (3)drying said molded container; (4) spraying a barrier layer directly toan inside surface of said container; (5) drying said container; (6)spraying a sealant layer directly on top of said barrier layer; (7)drying said container; (8) curing said container; (9) adding foodproducts into said container; and (10) sealing said container with saidformed top.
 20. The method of claim 19 wherein said process steps 4-6are at least repeated twice to apply plural barrier and sealant layers.21. The method of claim 19 further comprises the steps of: (11)positioning a condiment package on an outside surface of said formedtop; and (12) affixing a packaging label around said container and saidcondiment package.
 22. The method of claim 19 further comprises thesteps of: (11) positioning a condiment package inside of said container;and (12) affixing a packaging label around said container and saidformed top.
 23. The method of claim 19 wherein said process steps dogenerate no waste water.